Building-integrated solar photovoltaic panel

ABSTRACT

A device to generate electricity from solar rays is provided. A photovoltaic solar cell unit comprises a first cover and a second cover. The second cover is generally parallel to the first cover and the second cover is spaced from the first cover. The first and the second cover have a longitudinal axis. The photovoltaic solar cell unit also includes a solar cell disposed between the first cover and the second cover with the solar cell being disposed at a predetermined angle relative to the longitudinal axis.

CROSS REFERENCE TO RELATED PATENT APPLICATIONS

The instant patent application claims priority to U.S. ProvisionalPatent Application No. 61/276,386 to Luo et al. filed on Sep. 12, 2009,and which is herein incorporated by reference in its entirety and claimspriority to U.S. Provisional Patent Application No. 61/276,387 to Luo etal., which has common inventors and filed on Sep. 12, 2009, and which isalso herein incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present disclosure relates generally to a solar photovoltaic panel,particularly to a building-integrated photovoltaic panel.

2. Background

The efficiency of solar photovoltaic panel is dependent on the angle ofthe light radiated on the solar cell. For application inbuilding-integrated photovoltaic, to maximize solar access and poweroutput, the orientation and the tilt angle of the arrays are optimized.The orientation and the tilt angle of the arrays can be optimizedrelative to the geographical location. Demonstrations have shown that asystem installed at a tilt angle equivalent to the site latitudeproduces the greatest amount of electricity on an annual basis. Incomparison to a system's performance at latitudes angle, the annualperformance losses for vertical façade systems can be as high as 50%,while annual performance losses for façade systems can be as high as 10%for horizontal installation.

Facades offer a large area for solar panels. Besides generatingelectricity, solar facades can be integrated with window, day lighting,shading schemes to provide multiple benefits. The typical building skinfaçade is vertical and has a face that faces southwards. However,vertical oriented solar panels mostly have much reduced electricityoutput compared to panels sloped towards the sun. The reduction inoutput is greatest in the summer when the sun is high in the sky.Coincidentally, summer is also when electricity is the most valuable.Optimizing solar panel performance in building wall applications willusually require more complex detailing and therefore higher constructioncosts in order to accommodate optimal orientations to the sun. Currentlythere are a number of solutions in an attempt to improve efficiency andenergy output of solar panel used in building. Some of these solutionsattempt to make a sloped wall. The solutions of the prior art generallyhave drawbacks and reduce the effective floor areas at perimeter of thebuilding. The prior solutions also reduce building area per site areaand the solutions increase cost to construct. Other solutions attempt touse a saw tooth configuration or an accordion wall configuration, butthese solutions have complex curtain wall constructions, which are hardto manufacture and also potentially has problems, when cleaning. Stillother solutions seek to use solar cell blind to track the sun. But thisconfiguration also has performance loss from shading effects. Thisconfiguration also has reliability issues.

For installation on a flat roof top, solar panels are tilted at afavorable angle by using mounting structures. The mounting structurescause detrimental issues. These may include a high system cost and acomplex installation or a large weight load. Sometimes mounting of thepanels may even cause mechanical damage to the roof. Also the shading ona panel from adjacent panels will cause performance loss, as well asreliability issues. To avoid this problem, panels are placed separatedfrom one other by a large distance from each other to avoid shading,which can block the solar cell. As a result, the effective area from thesun to expose the solar panels is reduced. Also for a fixed roof areaand a fixed shape, due to the fixed dimension of a solar cell panel,there will be wasted area on the edges. This can result in losses, whichcan be high due to the large dimension of a solar panel.

For locations with latitude at 0 degrees, most roof tops are constructedto be sloped due to rain and drainage. However, the solar energyefficiency is the highest when the solar cell is horizontal.

It would be desirable to have a solar panel that has less performancedependency on design. More often than not, the strong performancedependency on design makes designers view the solar cell design as alimitation rather than an opportunity to exploit. Many architects andclients feel that solar architecture implies rigid design limitations.These limitations are regarding orientation, placement of windows,sloping roof elements, sun spaces and so on. This is not necessarilytrue as discovered by the present inventors.

It would be desirable to have a device that generate electricity fromsolar, which has high efficiency even at a standard vertical buildingstructure, without adding complexity in building design.

It would be desirable to have a solar panel that has high solarefficiency with a standard building construction, which has lower cost,better appearance, standard dimension, and a better design flexibility.

Furthermore, it would also be desirable to have a solar panel that has ahigh solar efficiency without sacrificing building floor area ascompared with a sloped building wall with a conventional solar panel.Building floor area is a precious commodity. In some cases, such assloped curtain wall, the solar panel configurations reduce the amount ofusable perimeter floor area. This is attributed to the fact that thewall effectively ‘cuts back’ on floor area as the building gets taller.Any reduction in usable floor area needs to be considered whenevaluating the life-cycle costs of a solar system.

Furthermore, it would be desirable to have a solar panel to form thebuilding structure with accessibility for frequent maintenance andcleaning of the panels from the exterior of the building. It is criticalto ensure that panel stays clean or can be cleaned to keep efficiency.Solar panel performance is highly dependent upon its ability to remainclean. Complicated construction designs, such as “saw tooth”, or“accordion”, have issues in that these configurations are difficult toclean. This in turn may affect the provision for cleaning tracks orfasteners in curtain wall systems and may increase operating costs.

Furthermore, it would be desirable to have a solar panel that can beinstalled on roof top with the panel having optimized energy efficiencywithout any special mounting system to tilt the panel against the rooftop. The present disclosure provides that the solar cell can be tiltedto optimum angle while panel is simply mounted on the roof top.

Still further, it would be desirable to have solar panels in a buildingstructure, which would not lose significant energy efficiency from thepartial shading from adjacent panel. Even partial shading on the panelwill decrease the energy output. Profiled mounting constructions, inparticular such as awnings, can produce shade. This shade falls alongthe edge of the adjacent panel. The shade will result in a loss ofefficiency. This also may cause reliability problems. In general, panelsneed a large distance between the panels. This large distance avoidsthis shading effect. However, the configuration has some majordrawbacks, including that the total area of solar panels is reduced, theconfiguration has a lower sun angle in spring and fall, there is toomuch sun exposed through the large distance.

Still further, it would be desirable to have solar panels that areadjustable to optimize heat load. It is desirable to have solar cellswith a high angled direct sunlight parameter to reduce heat load.

Still further, it would be desirable to have solar panels that areadjustable to optimize the daylight. The present disclosure may providethat the solar cells preferably shade high angle direct sunlight andallow diffuse light in through the space between solar cells. Diffuselight provides more comfortable lighting.

Still further, it would also be desirable to have a solar panel that hasmore solar cell area, so the cell can generate more electricity.Standard panel has a solar cell area at panel area minus empty space onpanel surface. With angled solar cells inside panels, solar cell areacan be larger than the panel area.

Still further, it would also be desirable to have a solar panel usingreflector. The reflector may collect sunlight on empty spaces betweenadjacent solar cells to improve panel efficiency. With angled and spacedsolar cells, angled reflectors that are inserted in between adjacentsolar cells can guide the sunlight to the surface of solar cells.

Still further, it would be desirable to have a device that can form acurved solar panel to provide the flexibility in architectural design.Still further, it would be desirable to have a curved solar panel withinternal solar cells having similar angles of incidence to avoidmismatch. Patterns can be designed to align solar cells. This design maypoint to the sun at the same angle even when the panel is curved.

Still further, it is desirable to have solar panels that optimize solarcell orientation as well. A vertical saw tooth design is used to obtaingood solar performances in certain orientations. However, this designcreated multiple “corner” windows, which is not favorable. With thepresent disclosure, a vertical straight curtain wall can be built, andthe internal solar cells will form the preferred orientation.

Still further, it is desirable to have reliable solar panel. There wassolution to have solar sunscreen within a window to track sun. However,due to the moving parts of the design, this configuration includesreliability issues. The present disclosure includes solar cells, whichare fully encapsulated in a panel, and thus there is no reliabilityconcern.

Still further, it is desirable to have solar panel without self shadingfrom an adjacent cell. In a solar sunscreen system, as result oftracking the sun, the shading from the above solar cell strongly limitsenergy yield. The present disclosure uses fixed designed angles andspaces to eliminate or to minimize the self-shading impact from an aboveor an upper solar cell. The space between solar cells is used to betransparent, as well as avoiding shading on an adjacent solar cell.

Therefore, there currently exists a need in the industry for a deviceand associated method that has a number of solar cells that are angledand that are spaced inside the panel.

SUMMARY OF THE INVENTION

The present disclosure advantageously fills the aforementioneddeficiencies by providing a method to make solar photovoltaic panelswith internal angled solar cells. The present disclosure device isunique when compared with other known devices and solutions because thepresent disclosure provides: a solar cell is strip shaped and rotatedalong the strip to form an angle with the surface of the solar panel.The solar cell points to sunlight at a favorable angle with a simpleconstruction and solar cells are spaced to minimize shading from anadjacent cell and connectors are patterned to assemble with the angledsolar cells. The solar cell may also include a patterned holder, or afront cover, or a back cover, which can be used to support the solarcell. The solar cell may further include an insert unit. The insert unitcan be added in the space between solar cells for functions ofinsulation, lights, or light collection.

According to a first aspect of the present disclosure there is provideda photovoltaic solar cell unit comprising a first cover and a secondcover. The second cover is generally parallel to the first cover. Thesecond cover is spaced from the first cover and the first and the secondcover have a longitudinal axis. The photovoltaic solar cell unit alsoincludes a solar cell. The solar cell disposed between the first coverand the second cover with the solar cell being disposed at apredetermined angle relative to the longitudinal axis.

According to another aspect of the present disclosure there is provideda photovoltaic solar cell unit comprising a first cover having alongitudinal axis and a solar cell disposed at a predetermined anglerelative to the longitudinal axis.

According to yet another aspect of the present disclosure there isprovided a photovoltaic solar cell unit comprising a first cover and asecond cover being generally parallel to the first cover. The secondcover is spaced from the first cover and the first and the second coverhave a longitudinal axis. The second cover is adapted to be supported onan inclined surface and a solar cell is disposed between the first coverand the second cover. The solar cell is disposed at a predeterminedangle relative to the inclined surface. The solar cell is generallyhorizontal notwithstanding the inclined surface.

In another embodiment there is provided a photovoltaic solar cell unitcomprising a first cover and a second cover being generally parallel tothe first cover. The second cover is spaced from the first cover and thefirst and the second cover having a longitudinal axis and a solar cellis disposed between the first cover and the second cover and the solarcell is supported on a curved surface.

In another embodiment there is provided a photovoltaic solar cell unitcomprising a first cover and a second cover being generally parallel tothe first cover with the second cover being spaced from the first coverand the first and the second cover have a longitudinal axis. Thephotovoltaic solar cell unit has a solar cell disposed between the firstcover and the second cover with the solar cell being disposed at apredetermined angle relative to the longitudinal axis. The photovoltaicsolar cell unit also has a holder between the first cover and the secondcover for supporting the solar cell.

The present disclosure now will be described more fully hereinafter withreference to the accompanying drawings, which are intended to be read inconjunction with both this summary, the detailed description and anypreferred and/or particular embodiments specifically discussed orotherwise disclosed. This disclosure may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided byway of illustration only and so that this disclosure will be thorough,complete and will fully convey the full scope of the disclosure to thoseskilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a simplified three dimensional sketch of prior art solarpanel.

FIG. 1B shows a simplified three dimensional sketch of solar panel ofthe present disclosure.

FIG. 2A shows a simplified three dimensional sketch of building wallwith saw tooth or accordion construction using prior art solar panel.

FIG. 2B shows a simplified three dimensional sketch of vertical façadewall using the present solar panel.

FIG. 3A shows a simplified three dimensional sketch of solar array on aflat roof top using prior art solar panel.

FIG. 3B shows a simplified three dimensional sketch of solar array on aflat roof top using the present solar panel.

FIG. 4A shows a simplified three dimensional sketch of solar array on asloped roof top using prior art solar panel.

FIG. 4B shows a simplified three dimensional sketch of solar array on asloped roof top using the present solar panel.

FIG. 5A shows a simplified three dimensional sketch of curved solarpanel, comprising of curved front cover, solar cell, curved back cover.

FIG. 5B shows simplified three dimensional sketch of curved solar panelwith internally angled solar cells pointing to same direction.

FIG. 6 shows a simplified three dimensional sketch of a solar panelusing connectors to assemble solar cells.

FIG. 7 shows a simplified three dimensional sketch of a solar panel witha patterned holder to support solar cells to a predetermined placement.

FIG. 8 shows a simplified three dimensional sketch of a solar panelusing patterned back cover to support solar cells to a predeterminedplacement.

FIG. 9 shows a simplified three dimensional sketch of an embodiment ofthe disclosure, with pattern on the front side of front cover.

FIG. 10 shows a simplified three dimensional sketch of a solar panelwith insert unit in a space between solar cells.

FIG. 11 shows a simplified three dimensional sketch of a solar panelwith a thin film solar cell on a patterned back cover.

FIG. 12 shows a simplified three dimensional sketch of a solar panelwith a reflective layer covering the exposed back cover.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure is directed to a method to make a solar panel,particularly for building integrated photovoltaic panel. The presentdisclosure is directed to a solar panel with an internal angled andspaced number of solar cells, which is made up of the followingcomponents, but not limited to: a) at least one solar cell, b)connector, c) a front cover, d) a back cover and e) encapsulant. Theprocesses to make the solar panel include a) a process to design anglesof solar cells, b) a process to design the width of solar cell, c) aprocess to design the space between solar cells, d) a process toassemble solar cells and e) a process to form a solar panel.

Examples related to the disclosure are disclosed. In the followingdescription, numerous specific details are set forth in order to providea thorough understanding of the present disclosure. However, to onehaving ordinary skill in the art, it will be apparent that the specificdetail need not be employed to practice the present disclosure.Well-known methods related to the implementation are not described indetail in order to obscuring the present disclosure.

FIG. 1A shows a simplified three dimensional sketch of prior art solarpanel 100. The panel 100 has a front cover 101, an encapsulant 102, asolar cell 103, and a back cover 104. The solar cell 103 is generally awafer cell with dimension 125 mm by 125 mm or 156 mm×156 mm. Variousconfigurations are possible. The front surface 105 of the solar cell 103is in parallel with the front surface 106 of the solar panel 100. As thethickness of the whole panel is generally below 20 mm, it is impossibleto tilt a full wafer cell to an obvious angle.

FIG. 1B shows a simplified three dimensional sketch of presentdisclosure. The solar panel 100′ has a front cover 101, an encapsulant102, a solar cell 103′, and a back cover 104. The solar cell 103′ is astrip. The strip has a width pf 1 to 20 mm, which can be obtained bycutting a solar wafer cell. The solar cell strip 103′ rotates along thestrip to form an angle with the front surface 106 of solar panel 100′.The surface 105′ of the solar cell 103′ forms an angle, which is between0 degree and 90 degree, with the surface 106 of the solar panel 100′.The encapsulant 102 may be many different elements include polymers,air, vacuum, inert gas, or similar materials, depending on themanufacturing process of the solar panel 100′. Front cover 101 and backcover 104 may be made of glass, polycarbonate, acrylic, laminated sheet,any combination thereof or similar materials. Solar panels may bedirectly laminated with insulation or can be incorporated into amulti-layer air or gas-filled insulating units. Processes to make thepanel include, but not limited to: lamination, cast in place resin, andan insulating glass process. As can be seen from FIG. 1A, the presentdisclosure includes a front cover 101 and a back cover 104 that aregenerally orthogonal or rectangular shaped members that include alongitudinal axis that is generally parallel to one another. The solarcells 105′ are captured between the front cover 101 and the back cover104 and may be in an encapsulant 102. Preferably, the solar cells 105′are each tilted at a predetermined angle with regard to the longitudinalaxis of the front cover 101 and the back cover 104 so that an edge ofthe solar cells 105′ points to the front cover 101 while a second edgepoints to the back cover 104. The predetermined angle is preferably anyangle that can result in an increased energy collection from the solarcells 105′ as previously described and known while keeping the frontcover 101 generally flat and the back cover 104 generally flat as well.

FIG. 2A shows a simplified three dimensional sketch of a building wallwith saw tooth or an accordion construction 200 using a solar panel 201,which is vertical at the floor 204, and which has a number spaced slopedsections 202 on the wall. Solar panel 201 is installed on the slopedportion 202 to tilt at an angle relative to the horizontal floor 204.Solar cell 203 is as result tilted at an angle to horizontal 204. FIG.2B shows a simplified three dimensional sketch of vertical wall 200′using the present solar panels 201′. By using the solar panel 201′, fora straight vertical façade wall 200′, solar cells 203′ are tilted at anangle to horizontal floor 204. As can be seen from FIG. 2B, the presentdisclosure includes a front cover vertical wall 200′ and a back coverthat are generally orthogonal or rectangular shaped members that includea longitudinal axis that is generally parallel to one another and arevertically disposed. The solar cells 203′ are captured within thevertical wall 200′ and may be in an encapsulant 102. Preferably, thesolar cells 203′ are each tilted at a predetermined angle with regard tothe longitudinal axis of the wall 200′. The predetermined angle ispreferably any angle that can result in an increased energy collectionfrom the solar cells 203′ as previously described and known whilekeeping the wall 200′ generally flat while the cells 203′ can be spacedfrom one another within the wall 200′ so they do not block one anotherin a vertical arrangement. Further, the outer wall 200′ is easier toclean.

FIG. 3A shows a solar array 300 on a flat roof top 305 using prior artsolar panel 301. To optimize energy generation, the solar panel 301 ismounted on a frame 302 to tilt the panel 301 to a favorable angle. Toavoid the shading from adjacent panel, a space 304 is left betweenpanels 301. For the length of the roof top shown here, about threepanels are installed. FIG. 3B shows a solar array 300′ on a flat rooftop 305 using the solar panel 301′. The solar panel 301′ is mounted flaton the roof top 305 without using frame. The solar cell 303′ is at anangle with a solar panel surface, and the solar cell 303′ therein istilted at an angle. As the solar panel is flat and there is no shadingfrom adjacent panel, and there is no need of spaces located betweenpanels to avoid the shading. For the length of the roof top shown here,four panels are installed, instead of three panels for the embodimentshown in FIG. 3A. Clearly for the panels with the same power, the arraywith present disclosure solar panel has 33% higher power than array withprior art solar panel. For the flat roof top solar array, thisembodiment has several advantages, such as saving cost of tilt mountingframe, simplifying the installation, avoiding loading and avoidingpossible damage to roof, as well as higher coverage area ratio andresulted higher electricity generation. As can be seen from FIG. 3B, thepresent disclosure includes a structure similar to those discussed abovethat is generally orthogonal or rectangular shaped that include alongitudinal axis. The solar cells 303′ are captured therein and may bein an encapsulant 102. Preferably, the solar cells 303′ are each tiltedat a predetermined angle with regard to the longitudinal axis so that anedge of the solar cells 303′ points to a top side while a second edgepoints to the bottom side. The predetermined angle is preferably anyangle that can result in an increased energy collection from the solarcells 303′ as previously described and known while keeping the structuregenerally flat to support it on a roof 305 as shown. Solar cells 303′preferably are also not blocked by an adjacent solar cell and include abetter ease of operation and installation.

FIG. 4A shows a simplified three dimensional sketch of solar array 400on a sloped roof top 402 using prior art solar panel 401. To reduceaccumulation of rain or snow, lots of roof tops are constructed to besloped. For prior art solar panel, the solar panel 401 mounted on thesloped roof top has solar cell 403. Solar cell 403 is tilted at theangle of sloped roof top. This may cause loss of electricity generationas explained above. As an example, for location with latitude around 0degrees, this may cause about 10% electricity losses. FIG. 4B shows asimplified three dimensional sketch of solar array 400′ disposed on asloped roof top 402 using the present disclosure solar panel 401′. Dueto the internal angle of solar cell 403′, when the solar panel 401′mounted on the sloped roof top, the solar cells is generally disposedhorizontal or not aligned with the sloped roof top, which isadvantageous. For location with latitude around 0 degrees, solar cell403′ has about 10% higher electricity than that measured with prior artsolar panel shown in FIG. 4A. The present disclosure can be used to tiltsolar cell to a favorable angle without the constraint of the solarpanel installation, which is very advantageous. As can be seen from FIG.4B, the present disclosure includes a generally rectangular shapedmember 401′ that include a longitudinal axis. The solar cells 403′ arecaptured therein and may be in an encapsulant 102. Preferably, the solarcells 403′ are each tilted at a predetermined angle with regard to thelongitudinal axis so that an edge of the solar cells 403′ points a topside of the structure 401′ while a second edge points to the bottom sideof the structure 401′. The predetermined angle is preferably any anglethat can result in an increased energy collection from the solar cells403′ as previously described and known while keeping the structure 401′generally flat. As can be seen regardless of the inclined surface, thesolar cells 403′ can be disposed generally horizontally or at zerodegrees while keeping the top side of the structure 401′ generally flatfor ease of operation.

Furthermore, the method associated with the present disclosure may alsoinclude a process for producing a curved solar panel. FIG. 5A shows asimplified three dimensional sketch of a curved solar panel 500. Thecurved solar panel 500 includes a curvature along at least one axis ofthe solar panel 500. The solar panel 500 has a curved front cover 501, asolar cell 502, and a curved back cover 503. The solar cells 502 form acurve surface or plane, which is disposed in parallel to the panelsurface 501. The solar cell efficiency strongly depends on solarincident angle. The solar cells 502 pointing to sun at different anglesthen there is mismatch between them, which results in efficiency lossand hot spots, which may cause reliability problems. FIG. 5B shows asimplified three dimensional sketch of curved solar panel 500′. Thecurved solar panel 500′ includes a curved front cover 501, a solar cell502′, and a curved back cover 503. Solar cells 502′ are tiltedinternally so the solar cells 502′ point to the sun at the same angle.As can be seen from FIG. 5A, the present disclosure includes a curvedfront cover 502 and a back cover 503 that is also curved by apredetermined amount to form two U shaped members. The solar cells 502are supported by a curved surface 503 and may be in an encapsulant 102.Preferably, the solar cells 502′ are each tilted at a predeterminedangle. The predetermined angle is preferably any angle that can resultin an increased energy collection from the solar cells 502′ aspreviously described. FIG. 5A shows that the solar cells 502′ aregenerally aligned with one another while FIG. 5 b shows that the solarcells 502′ are staggered from one another. Each solar cell 502′ may beangled depending on a location on the curved surface.

FIG. 6 shows a simplified three dimensional sketch of one embodiment ofthe present disclosure using a number of connectors to assemble solarcells. The solar panel 600 is comprised of a front cover 601, anencapsulant 602, a back cover 603, a front connector 604, a solar cell605, and a back connector 606. The connectors 604 and 606 are patternedand hold solar cells to the designed placement as shown in FIG. 6. Theconnectors 604 and 606 are used to assemble solar cells 605 together andto form solar cell assembly. The connectors 604, 606 and the solar cells605 are combined with front cover 601 and back cover 603 to make a solarpanel 600. As can be seen from FIG. 6, the present disclosure includes afront cover 601 and a back cover 603 that are generally orthogonal orrectangular shaped members that include a longitudinal axis that isgenerally parallel to one another and are vertically disposed. The solarcells 605 are captured between the front cover 601 and the back cover603 and may be in an encapsulant 602. Preferably, the solar cells 605are each tilted at a predetermined angle with regard to the longitudinalaxis of the front cover 601 and the back cover 603 so that an edge ofthe solar cells 605 points to the front cover 601 while a second edgepoints to the back cover 603. The predetermined angle is preferably anyangle that can result in an increased energy collection from the solarcells 605 as previously described and known while keeping the frontcover 601 generally flat and the back cover 603 generally flat as well.Preferably, the connectors 604 and 606 are resilient members that holdthe solar cells 605 in place.

FIG. 7 shows a simplified three dimensional sketch of another embodimentwith a patterned holder. The patterned holder 707 preferably is used tosupport solar cells to a predetermined placement. The solar panel 700includes a front cover 701, an encapsulant 702, a back cover 703, afront connector 704, a solar cell 705, a back connector 706 and apatterned holder 707. The connectors 704 and 706 are patterned to matchthe pattern of the patterned holder 707. The connectors 704 and 706 andsolar cells 605 are assembled and then combined with front cover 701,back cover 703, and holder 707 to form a solar panel 700. The patternedholder 707 can be manufactured with varying materials, such as metal,plastic, glass, and PCB and any combination thereof. The solar cells canbe connected together by independent connectors, or by connectorsembedded in the holder, such as PCB board, or similar materials.

Another embodiment of the present disclosure includes a solar panel withpattern 807 on a front cover or a back cover to support solar cells. Asan example, the patterned glass can be used as a front cover or a backcover. The pattern supports solar cells. FIG. 8 shows a simplified threedimensional sketch of another embodiment of the present disclosure usinga patterned back cover to support the solar cells in the desireddesigned placement. The solar panel 800 includes a front cover 801, anencapsulant 802, a back cover 803, a front connector 804, a solar cell805, and a back connector 806. The back cover 803 is patterned on theinternal side with the pattern 807 to support the solar cells. Theconnectors 804 and 806 are patterned to match the pattern 807 of theback cover 803. Patterned of the back cover can be made with varyingmaterials, such as a patterned glass, patterned plastic sheet. Theexample here is a patterned back cover. Another option is a similarlypatterned front cover on the internal side. Preferably, the patternedfront cover on the internal side is to hold solar cells in the designedplacement.

Furthermore, the subject matter of the present disclosure is a processfor producing a solar panel. The process makes available a bodycomprising a number of solar cell units with the solar cell units beingparallel to each other, while cell surface is tilted to the panelsurface at an angle. The solar cell is preferred to be strips and thesolar cell can be rotated along the strip. There are different optionswithin the scope of the present disclosure. One example is thatcrystalline Si solar cell is sliced into a number of strips. Anotherexample is that the present disclosure may include a number of flat thinfilm solar cell is sliced into strips. Another example is that thepresent disclosure may include a thin film solar cell being directlyformed on strips.

In additional to changing tilted angle, the present disclosure mayinclude a differently configured solar cell orientation as well. Thecurrent vertical saw tooth design is preferably used to obtain animproved solar performance in certain orientations. However, this designcreated multiple “corner” windows, which is not favorable. With thepresent disclosure, the vertical straight curtain wall can be built,while internal solar cells form a preferred orientation.

Another embodiment of the present disclosure includes a pattern on thefront side of the front cover. Pattern preferably is intended to reducethe reflective light loss at the panel surface. Due to the refractiveindex mismatch between air and glass, a portion of the sunlight isreflective back to air at the interface of the air and the glass. Theratio of reflection increases with a decrease of the angle between thelight and the interface. For a standard solar glass, the reflectionpercentage is 4.0% at 90°, 5.77% at 50°, and 8.9% at 60°. With thepattern on the panel surface, the glass interface is tilted toward thesun. This reduces the incidence angle by the tilted angle of thepattern. FIG. 9 shows a simplified three dimensional sketch of anembodiment of the present disclosure with a pattern 907 on a front sideof the front cover 901. The panel includes a patterned front cover 901,an encapsulant 902, a patterned back cover 903, a front connector 904, asolar cell 905 and a back connector 906. The front cover 901 and backcover 903 can be a patterned glass sheet.

Solar cells are separated from each other by a space having apredetermined distance. The space preferably avoids the shading from anadjacent cell. When the panel is translucent, such as glass-on-glass,the space provides for daylight control and heat load control. Theamount of sunlight may be controlled and the solar panel may receivemore diffused light, and less direct light, or more light in the summer,or more light in morning and afternoon, and less night at noon. Heatload may also be controlled. For example, more heat load in winter, orless heat load in summer, or more heat load in morning and afternoon,and less heat load at noon.

Furthermore, the method associated with the present disclosure may alsoinclude inserting a unit 1005 into the space between solar cells toprovide functionality. The insert unit 1005 can be different types, suchas insulator, bypass diode, LED diode, or light reflector or any otherunit 1005 that provides functionality. FIG. 10 shows a simplified threedimensional sketch of a panel comprising a front cover 1001, anencapsulant 1002, a solar cell 1003, a back cover 1004, and an insertunit 1005. As an example, the insert unit 1005 can be insulating unit toinsulate front connect and back connector 1006. The insert unit 1005 canalso be semiconductor device to form both isolation and functionaldevice. As an example, a diode chip can be inserted. The diode chip mayact as bypass diode for the solar cell. This eliminates the currentlimited from a bad cell. The diode is operatively connected to solarcell in a way that there is only low leakage current during normaloperation. However, when the cell is malfunctioning and become reversebiased, then the diode activates and leads the current through thediode. As another example, the insert unit 1005 can be a LED chip, whichprovides an illumination in night. As another example, the insert unit1007 can be a reflective unit, which reflects light onto the surface ofsolar cell 1003 to improve energy generation by the solar cell 1003.

Furthermore, the method may also include a process for producing a thinfilm solar cell on a patterned front cover or a back cover. The benefitis higher energy output and efficiency. This results in a larger solaraccess of the solar cell and an improved sun incident angle and improvedthin film solar cell area. FIG. 11 shows a simplified three dimensionalsketch of the thin film solar panel 1100. The thin film solar panel 1100has a front cover 1101, an encapsulant 1102, a solar cell 1103, and aback cover 1104. Solar cell 1103 is disposed on the pattern back cover1104. The thin film solar cell can be formed on the pattern back coverby deposition, spray or any other process known in the art. The spacebetween cells can be formed by cutting, shuttering during deposition,laser cutting or other process. The solar cell can be applied to patternfront cover or can be applied to the holder as well.

Furthermore, the method associated with the present disclosure may alsoinclude a process to direct light in a space formed in the solar cell sothat same electricity generation can be realized by fewer solar cells.FIG. 12 shows a simplified three dimensional sketch of a solar panel1200 with a reflective layer 1205 covering exposed back cover 1204. Inthis example, the reflective layer 1205 is on the patterned back cover1204 and the reflective layer 1205 is exposed between the solar cells1203. The reflection layer 1205 can be formed on the pattern back coverby a coating, a deposition process, a spray or other process known inthe art to provide a reflection. Reflection layer 1205 can cover thespace between the solar cells, or disposed on the whole surface of theback cover. The same idea can be applied to pattern front cover or topattern the holder with the layer. Reflection layer 1205 may be titaniumdioxide, a mirror or the like.

While the present disclosure has been described above in terms ofspecific embodiments, it is to be understood that the disclosure is notlimited to these disclosed embodiments. Many modifications and otherembodiments of the disclosure will come to mind of those skilled in theart to which this disclosure pertains, and which are intended to be andare covered by both this disclosure and the appended claims. It isindeed intended that the scope of the disclosure should be determined byproper interpretation and construction of the appended claims and theirlegal equivalents, as understood by those of skill in the art relyingupon the disclosure in this specification and the attached drawings.

1. A photovoltaic solar cell unit comprising: a first cover; a secondcover being generally parallel to the first cover, the second coverbeing spaced from the first cover, the first and the second cover havinga longitudinal axis; and a solar cell disposed between the first coverand the second cover, the solar cell being disposed at a predeterminedangle relative to the longitudinal axis.
 2. The photovoltaic solar cellunit of claim 1, further comprising a plurality of solar cells beingaligned between the first cover and the second cover with each of theplurality of solar cells being disposed at a predetermined anglerelative to the longitudinal axis.
 3. The photovoltaic solar cell unitof claim 1, further comprising an encapsulant between the first coverand the second cover.
 4. The photovoltaic solar cell unit of claim 1,wherein the solar cell disposed between the first cover and the secondcover is tilted and wherein the solar cell has a second longitudinalaxis, the second longitudinal axis intersecting the longitudinal axis ofthe first and the second cover, and wherein the solar cell includes afirst end tilted toward the first cover and a second end opposite thefirst end tilted toward the second cover.
 5. The photovoltaic solar cellunit of claim 1, wherein the solar cell, the first cover and the secondcover are aligned vertically.
 6. The photovoltaic solar cell unit ofclaim 1, wherein the solar cell, the first cover and the second coverare aligned horizontally.
 7. A photovoltaic solar cell unit comprising:a first cover having a longitudinal axis; and a solar cell beingdisposed at a predetermined angle relative to the longitudinal axis. 8.The photovoltaic solar cell unit of claim 7, further comprising anencapsulant covering the solar cell.
 9. The photovoltaic solar cell unitof claim 7, further comprising a plurality of solar cells with each ofthe plurality of solar cells being disposed at a predetermined anglerelative to the longitudinal axis.
 10. The photovoltaic solar cell unitof claim 7, wherein the solar cell has a second longitudinal axis, thesecond longitudinal axis intersecting the longitudinal axis, and whereinthe solar cell includes a first end tilted toward the first cover and asecond end opposite the first end.
 11. The photovoltaic solar cell unitof claim 7, further comprising a second flat member being a second coverdisposed spaced from the first cover, the first cover being flat andoperable to be mounted on a flat surface.
 12. A photovoltaic solar cellunit comprising: a first cover; a second cover being generally parallelto the first cover, the second cover being spaced from the first cover,the first and the second cover having a longitudinal axis, the secondcover being adapted to be supported on an inclined surface; and a solarcell disposed between the first cover and the second cover, the solarcell being disposed at a predetermined angle relative to the inclinedsurface, wherein the solar cell is generally horizontal notwithstandingthe inclined surface.
 13. The photovoltaic solar cell unit of claim 12,further comprising an encapsulant between the first cover and the secondcover.
 14. The photovoltaic solar cell unit of claim 12, furthercomprising a plurality of solar cells being aligned between the firstcover and the second cover with each of the plurality of solar cellsbeing disposed at the predetermined angle.
 15. The photovoltaic solarcell unit of claim 12, wherein the solar cell disposed between the firstcover and the second cover is generally horizontal and wherein the solarcell has a second longitudinal axis, the second longitudinal axisintersecting the longitudinal axis of the first and the second cover.16. A photovoltaic solar cell unit comprising: a first cover; a secondcover being generally parallel to the first cover, the second coverbeing spaced from the first cover, the first and the second cover havinga longitudinal axis; and a solar cell disposed between the first coverand the second cover, the solar cell being supported on a curvedsurface.
 17. The photovoltaic solar cell unit of claim 16, furthercomprising a plurality of solar cells being between the first cover andthe second cover with each of the plurality of solar cells beingsupported by the curved surface.
 18. The photovoltaic solar cell unit ofclaim 16, further comprising an encapsulant between the first cover andthe second cover.
 19. The photovoltaic solar cell unit of claim 16,wherein the solar cell disposed between the first cover and the secondcover, and wherein at least one of the first or the second cover iscurved to support the solar cell.
 20. The photovoltaic solar cell unitof claim 17, wherein the solar cells are aligned, or wherein the solarcells are staggered relative to one another.
 21. A photovoltaic solarcell unit comprising: a first cover; a second cover being generallyparallel to the first cover, the second cover being spaced from thefirst cover, the first and the second cover having a longitudinal axis;and a solar cell disposed between the first cover and the second cover,the solar cell being disposed at a predetermined angle relative to thelongitudinal axis; and a holder between the first cover and the secondcover for supporting the solar cell.
 22. The photovoltaic solar cellunit of claim 21, further comprising a plurality of solar cells beingaligned between the first cover and the second cover with each of theplurality of solar cells being disposed at a predetermined anglerelative to the longitudinal axis, wherein the holder supports theplurality of solar cells.
 23. The photovoltaic solar cell unit of claim21, further comprising an encapsulant between the first cover and thesecond cover.
 24. The photovoltaic solar cell unit of claim 1, furthercomprising a reflective layer to direct light to the solar cell.
 25. Thephotovoltaic solar cell unit of claim 1, wherein the first cover or thesecond cover comprising a thin film solar cell.
 26. The photovoltaicsolar cell unit of claim 1, wherein the first cover or the second covercomprises a pattern to reduce losses from light transmitting through thefirst cover or the second cover.
 27. The photovoltaic solar cell unit ofclaim 1, further comprising a device operatively connected to the solarcell and disposed between the first cover and the second cover toprovide additional functionality to the solar cell.
 28. The photovoltaicsolar cell unit of claim 1, wherein the predetermined angle increases anamount of energy generated by the solar cell.
 29. The photovoltaic solarcell unit of claim 1, wherein the first cover or the second cover isflat.
 30. The photovoltaic solar cell unit of claim 1, furthercomprising a plurality of solar cells, wherein the plurality of solarcells are spaced from one another by a predetermined distance andcaptured in the first cover and the second cover.
 31. A photovoltaicsolar cell unit comprising: a first cover; a second cover beinggenerally parallel to the first cover, the second cover being spacedfrom the first cover, the first and the second cover having alongitudinal axis; and a plurality of solar cells disposed between thefirst cover and the second cover, wherein the solar cells are arrangedin an edge to edge orientation wherein the solar cells are tilted with afirst solar cell being tilted in a first configuration and a secondsolar cell being tilted in a second opposite configuration with thesolar cells forming a undulating pattern between the first cover and thesecond cover.